Large poster apparatus and method of constructing for back-lighted signboard

ABSTRACT

A large poster apparatus for a back-lighted signboard and a method of constructing same from a plurality of smaller poster sections, including improving the translucent quality of the poster material, aligning respective adjacent sections for exact image continuity, laminating a clear film over a first poster layer, laminating a second poster layer over the clear film, and applying heat and pressure to create a composite laminated poster apparatus having registered images throughout.

BACKGROUND OF THE INVENTION

This is a continuation-in-part of my U.S. patent application Ser. No.99,071, filed Nov. 30, 1979, now U.S. Pat. No. 4,244,769.

This invention relates to a large poster apparatus and method forconstructing large signboard posters, and specifically to postersadaptable for use in large signboards where back-lighting is used tocreate an illuminated poster image and thereby provide an enhancedvisual effect.

In the field of outdoor advertising as it relates to large billboardsthe typical and preferred method of applying a very large poster to abillboard is to apply it in sections or sheets. Each section istypically glued or pasted to the billboard surface by a worker skilledin this field using long handled brushes and other tools for thispurpose. The edges of adjacent sections are reasonably carefully alignedwhile the adhesive material is still in an unset condition so thatadjacent sections may be moved about over the billboard. The number ofsheets applied in this manner varies with the relative size of thebillboard, but it is not unusual to apply a dozen or more sections to abillboard in the size range of ten feet by twenty-four feet or larger.Billboard posters applied in this manner as typically made from posterpaper which has very little structural strength itself, but which whenadhered to a billboard surface will withstand normal weathering andexposure to the elements for a number of months.

Billboards and posters constructed according to the aforementionedprocedure may be illuminated for mighttime display, but suchillumination usually takes the form of directional lighting illuminatingthe front surface of the billboard from a position above or below thebillboard surface so as to create a minimum line of sight interferencewith the poster itself. Such lighting enhances the advertising value ofthe billboard by increasing the number of hours per day that thebillboard serves as an advertising medium.

It has been known that a number of advantages can be had by lighting abillboard from the rear surface, one of which is the obvious advantageof being able to house the electrical circuits and lighting fixtureswithin the billboard structure itself to avoid exposure to the elementsand to minimize damage from weather and vandalism. Further, aback-lighted billboard presents a more pleasing image which is somewhatsofter to view and is more likely to draw attention to the posterdisplayed on the billboard. Prior art poster images which have utilizedback-lighted signboards have most often been constructed usingphotographic techniques on film, usually utilizing only a single sheetof material for this purpose. Since it has not been possible to createvery large single sheet photographic images such back-lighted billboardshave typically been rather small in size and in no way approaching thesize of a standard outdoor billboard. When larger billboards have beenattempted to be constructed using a plurality of photographic images inedge alignment to create a large poster image, the problem of providingimperfect edge alignment has resulted in very visible lines of lightescaping between adjacent photographic sections. These edge lines resultfrom the back-lighting shining directly through the billboard surface,and they tend to be very distractive of the overall image and produce aresultant lower quality and less pleasing poster effect.

SUMMARY OF THE INVENTION

The present invention provides an apparatus and method for constructinglarge billboard posters from laminated sections which are bondedtogether to form a structurally strong yet translucent poster surface.The posters constructed according to the process are suitable forclamping or hanging over a translucent billboard surface without thenecessity for adhering the poster directly to the billboard surface,whereby they may be conveniently removed and replaced or removed andtransferred to a different billboard location without damage to theposter.

It is therefore a principal object of the invention to provide abillboard poster and process for manufacturing from a plurality ofindividual poster sheets, each sheet having thereon a portion of theoverall billboard image, to form a large poster having sufficientstructural strength to be hung, stretched, or otherwise clamped to aback-lighted billboard.

It is a further object of this invention to provide a process formanufacturing a large billboard poster having carefully edge-alignedsections and multiple laminated layers which are translucent.

It is yet another object of ths present invention to provide a largebillboard poster wherein multiple poster images are laminated togetherin precise image registration.

It is yet another object of the present invention to provide a posterwherein the poster has sufficient strength for self-supporting mounting.

Other objects and advantages will become apparent from a reading of theattached specification and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

A preferred embodiment and method is disclosed herein and with referenceto the appended drawings, in which:

FIG. 1 shows the construction of a large billboard poster from sections;

FIGS. 2A and 2B show the alignment steps for multiple images;

FIG. 3 shows the laminating apparatus;

FIG. 4 shows an intermediate step in the construction of a large poster;and

FIGS. 5A-5C show steps in the bonding of adjacent poster sections, andshow the laminated sections.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring first to FIG. 1 there is shown a large billboard poster 100constructed from the alignment of a plurality of sections 1-12. It ispresumed that each of the sections 1-12 contains a portion of theoverall image, which image is formed when all of the sections areproperly aligned as shown. In a poster used for a typical outdooradvertising billboard the size of poster 100 may be in the range of 6-12feet high by 12-30 feet wide, each of the sections 1-12 beingproportionately sized to form the necessary overall poster. Suchbillboard posters are typically constructed from a paper material of60-90 pound weight by a printing process, wherein each of the individualsections are separately printed, and with a printing process allowingfor some image overlap on adjacent edges which is preferably trimmed atthe time the poster is assembled. Commonly available poster paper is notinherently translucent, but is made translucent through some of theinventive steps described herein.

The preferred embodiment of the present method requies two overallposter images, and thereby it is necessary that each of sections 1-12 beprinted in duplicate according to the teachings of the invention. Thisis easily accomplished in practice, for printers who print such posterstypically print dozens, and even hundreds, of poster sections at a timefor distribution throughout a given advertising region. The presentinvention utilizes such printed poster sections in the form normallyproduced and without any change required to accepted printing practices.

FIG. 2A illustrates a first step in the process wherein identical posterimage sections are registered, one atop the other, preferably on a lighttable whereby the images may be precisely overlayed and aligned. Aplurality of locating holes is punched through both images after suchalignment in order that the identical images may be separated andsubsequently repositioned on pins through the locating holes to recoverthe precise alignment thus established. FIG. 2B shows poster sections 1,2 and 3 aligned together, where it is presumed that the edge alignmentbetween section 1 and section 2 is accomplished by means of carefulalignment of respective image parts and, similarly, edge alignmentbetween sections 2 and 3 is accomplished through careful imagealignment. Thus, the image itself permits vertical alignment of sections1, 2 and 3 of a plurality of poster sections, and the locating pins 120and 130 permit overlay registration of a second plurality of identicalposter sections.

The general procedure described above is followed for each of the postersections 4, 5, 6 and 7, 8, 9 and 10, 11, 12, or for as many postersections as any particular poster may utilize. As each of the sections,1, 2, 3 or 4, 5, 6, etc. is aligned according to the proceduresdescribed above there is some overlap between adjacent sheets wherein,for example, a portion of the image along the top edge of sheet 2 alsoappears along the bottom edge of sheet 1. This overlap is removed byusing a sharp edge to cut through the overlapped sheets and therebyprovide a precise edge alignment and a continuous image flowing betweensheet 1 and 2. Similarly, the overlap image may be removed from allother sheets wherein this occurs.

After each section of three vertically aligned sheets have been trimmedaccording to the above procedure the sheets are treated by immersion ina chemical solution to make the sheets translucent. The chemicalsolution preferably used for this purpose contains about 13% liquidsilicone at 50-100 ANGS viscosity and about 87% mineral spirits of thetype that meet the Form 66 Federal Standards for emission andevaporation. A liquid silicone which works well for the intended purposeis manufactured by General Electric Company as type SF 96-100. However,a variety of solutions may be prepared for this purpose, usingparaffins, waxes, oils, resins, and/or silicones, it being required thatthe solution impregnate the paper to render it translucent on a more orless permanent basis. The sheets are immersed in the solution for aperiod of 8-16 hours and are then removed for drying. Drying may beaccomplished in air in about 24 hours, or in an oven approximately 175°for 3-4 hours. This latter method preshrinks the sheets by apredetermined amount, which preshrinking has been found advantageous inpractice.

After the sheets have been treated according to the foregoingdescription they are ready for laminating according to the followingpreferred process. FIG. 3 shows a laminating table suitable for use inthis process, wherein a large size bed 200 has a plurality of spacedholes therethrough and over the entire bed surface, and wherein theholes are in communication with a vacuum chamber 210 beneath bed 200.Vacuum pumps 220 create a suction force through the holes to secure anysheet which is laid atop bed 200 tightly to the bed. The size of bed 200is preferably about 7 feet by 13 feet, which is sufficient toaccommodate a section of three poster sheets of approximately the samesize. A table top 250 is hinged at one end 260 so that it may be raisedabove bed 200. Table top 250 has a plurality of heating devices arrangedalong its lower surface so as to provide a uniform heating whichradiates downwardly. For example, one construction for this deviceutilized seventy-two 250 watt infra-red heat lamps uniformly spaced overthe undersurface of top 250. These heat lamps produce a temperature ofabout 200° F. over the surface of bed 200. Temperature sensors andcontrol circuitry may be mounted on the apparatus to control the bedtemperature to a desired setting. Three of the treated sheets, forexample sheets 1, 2, 3, are laid on bed 200 and positioned in preciseimage alignment. Vacuum pumps 220 are activated to create a suctionthrough the plurality of holes over bed 200 and to thereby securely holdthe sheets to the bed. Registration pins are placed through the holespreviously made along the edges of sheets 1 and 3 for purposes to behereinafter described.

Either of two lamination processes may be used hereafter. The firstprocess utilizes a clear polyester film of thickness 0.002-0.003 inches,which film has a thermosetting adhesive coated on its top and bottomsurface. The film is overlaid atop the sheets which are positioned onbed 200, leaving about a 6-inch edge uncovered along the edge of thesheets which are to be subsequently mated with sheets from an adjacentsection. Next, the matching three sheets are placed over theregistration pins and on top of the thermosetting laminate and they areprecisely aligned for good image quality. A silicone rubber blanket,approximately 1/16th inch thick, is rolled over the entire assembly andtop 250 is lowered to cover the silicone rubber blanket. The heat lampsin top 250 are turned on and the temperature controls are set tomaintain the temperature at just above the thermosetting adhesivemelting point. In a typical process the melting point is approximately200° F., and the vacuum pumps are selected so as to provide about 25pounds per square inch (psi) of pressure across the sheets, and thetemperature is applied for about fifteen minutes.

This process is repeated for each of the three sheet sections, in eachcase leaving about a 6-inch edge uncovered along sheets which are to bemated to adjacent sections. After this portion of the process iscompleted there is produced a plurality of laminated sections of posterhaving nonlaminated adjacent edges as illustrate in FIG. 4.

FIGS. 5A, 5B and 5C show a side view of a portion of the poster of FIG.4. Specifically, FIG. 5A shows a side view of a portion of sheets 3 and6, wherein the bottom poster layer of sheet 3 is shown as 3A and the topposter layer of sheet 3 is shown as 3B. Similarly, the bottom and topportions of sheet 6 are illustrated as 6A and 6B. A polyester film layer50 lies between the respective poster sheets, and an intermediate void51 extends along the respective sheet edges. FIG. 5B shows the processfor placing a strip of polyester film in void 51, wherein a strip ofclear polyester film 52 having thermosetting adhesive coated on top andbottom surfaces is placed in bridging relationship to sheets 3A and 6A,sheets 3B and 6B being raised to permit film 52 to be placed. FIG. 5Cillustrates the final step in the process of bonding adjacent sectionstogether, wherein a silicone rubber blanket 54 is laid over the adjacentsheet edges and pressure and heat are applied as described hereinbefore.

The aforementioned steps may be accomplished in the continuous processif a large table is used in addition to a laminator of the typedescribed herein. In this instance, the intermediate laminating layercontaining the thermosetting adhesive is applied first to the sheetscomprising an end section of the poster, and these sheets are then movedpartially through the laminator and the next adjacent sheets arepositioned and aligned for image continuity, and the heating process isrepeated for an intermediate polyester film layer bridging the twoposter sections. The portion of poster thus laminated is again partiallymoved through the laminator and the next adjacent poster sheets arealigned and the process steps are continually repeated until the entireposter is formed.

An alternative laminating process may be used with clear polyester filmhaving pressure sensitive adhesive coated on both sides of its surfaces.The adhesive typically has a 90-pound silicone treated paper lineroverlaying the surfaces to protect the adhesive. Using this alternativeprocess the bottom poster sheets are aligned as described before and oneside of the pressure sensitive adhesive is exposed by removing thesilicone treated paper from that side, and this surface is adhered tothe aligned bottom poster sheets by application of pressure. Next, anarrow strip of the silicone treated lines is removed from the topsurface of the film to expose a portion of the underlying poster image.The top sheet of the poster image is then positioned in good imageregistration using the exposed underlying sheet for this purpose and thetop sheet is adhered to the laminate by pressure application along theexposed strip. After the top sheet has been adhered in this manner theremaining silicone treated liner is removed and the remaining portion ofthe top sheet is similarly adhered to the laminate.

After an entire poster has been formed in this manner the edges aretrimmed to size and the poster may be hung or stretched over aback-lighted signboard. I have found it preferable to attach a metalstrip along top and bottom poster edges by any convenient attachingmeans, and to utilize this metallic strip as the means for attachment tothe billboard. The entire poster may be conveniently rolled fortransportation to a billboard, and may be readily hung on the billboardby merely attaching ropes or cables to the top metallic strip andraising the poster across the billboard surface. Once it is properlypositioned attachments may be made to the bottom metallic strip and byapplication of tension the poster may be stretched over the billboardsurface for display. Replacement of a poster attached in this way merelyinvolves the steps of relieving the tension holding the poster to thebillboard, lowering the top portion of the poster, lowering the posterfrom the billboard while again rolling it into a convenient size fortransport, and disconnecting the attachments to the metallic strips sothat it may be removed from the billboard. A poster may thus be hung ona billboard, removed and if desired transported to a second billboardfor reuse.

The present invention may be embodied in other specific forms withoutdeparting from the spirit or essential attributes thereof, and it istherefore desired that the present embodiment be considered in allrespects as illustrative and not restrictive, reference being made tothe appended claims rather than to the foregoing description to indicatethe scope of the invention.

What is claimed is:
 1. A method of constructing a large poster from aplurality of sheets containing image portions, for use on a back-lightedsignboard, comprising the steps of(a) immersing the plurality of postersheets in a liquid solution of a type which renders said sheets lighttranslucent, and removing the sheets from said solution and drying them;(b) aligning a first group of adjacent image sheets in abutting imageedge alignment; (c) overlaying the edge-aligned sheets with a clear filmlayer having adhesive surfaces (d) overlaying the clear film layer witha second group of matching image sheets and aligning said sheets inimage registration with said first group of sheets; and (e) forming alaminated whole from said first group, said clear film layer, and saidsecond group.
 2. The method of claim 1, wherein the step of immersing isdone for at least about 8 hours.
 3. The method of claim 2, wherein thestep of drying said sheets further comprises heating said sheets to atemperature of about 175° F. for at least 3 hours.
 4. The method ofclaim 1, wherein the step of forming a laminated whole further comprisesheating and compressing said first group, said clear film layer, andsaid second group.
 5. The method of claim 1, wherein the step ofoverlaying the edge aligned sheets with a clear film layer havingadhesive surfaces comprises overlaying all except a narrow edge of saidsheets, said sheets becoming a first plurality of sheets, and furthercomprising repeating steps a, b, and c for a second plurality of sheets,and placing said second plurality in edge abutting image alignment withsaid first plurality of sheets, and overlaying the respective narrowedges of said sheets not previously overlaid with a clear film layerhaving adhesive surfaces bridging said edge abutting sheets andintermediate said first and second group of matching image sheets, andforming a laminated whole from said first group, said clear film layerand said second group along said narrow edge.